On December 4, 2017, as the life cycle of products became shorter and shorter in many industries, this means that only the production system has the ability to meet the production process requirements, and the new generation or new version of the product can be grabbed. The market has a quick start to market. At present, the production mode is changing, and the integration of industry and the Internet is the key to achieving industrial transformation and upgrading. In order to solve the pain points of large-scale manufacturers in the face of a variety of different types of products must be produced in a short period of time, to help manufacturers seize market opportunities, from Germany's high-tech equipment manufacturer Manz Yazhi Technology, through the "Internet +" Organizing production systems enables high-volume production with a high degree of flexibility and customizability, eliminating setup time and minimizing production and greatly speeding lead times.
In the Internet + Industry 4.0 production environment, through the production system, combined with the Internet + development platform or product configurator, digital material database and logic sample production, it is possible to develop an extremely flexible and fully automated production line – such as the realization of Internet plus production Made in Germany and even cross-border production. By entering various requirements in a browser-based configurator, customers can directly participate in the production development process.
Due to the increasing variety of products, fully customized mass production or mass customization and a small number of customized products have become market trends. In order to meet these two needs, the equipment manufacturers must provide a high degree of reliability, standardization and automation to convert production modules in minutes or even seconds. Not only that, the production line needs to be fully digitized, so the concept of self-organizing production came into being in order to meet the reliable and economical production conditions required by the customized market.
Manz's self-organizing production system enables high-volume production with high flexibility and customizability: tool-free design capability and free programming. With these two capabilities, software can be used to achieve economical conversion without the need for time-consuming mold change processes. And the product changes can be completed in real time and fully automatically. This means that a variety of customized products can be produced, such as a large number of series, which greatly accelerates the lead time.
Dr. Martin Steyer, head of integrated solutions at Manz Group, believes that self-organized production concepts are mainly embodied in two levels: production process level and production logistics level. For the production process, Manz uses “tool-free†processing equipment, such as laser cutting or laser welding, which can be completely converted by software control programs. As the number of batches of series products is getting smaller and smaller, the amortization angle tends to shift to the additive manufacturing process. For example, in the new placement process developed by Manz, a variety of flexible materials are extracted from the reel, laser-cut, and then laminated together using the principle of layered production. This creates parts with a variety of shapes, colors or combinations of materials – for optimum stability of lightweight structures.
Picture 1: Practical application of the patching process: In the bicycle repair shop, the scanner can be used to measure the favorite hobby of the road bike, so as to determine its ideal sitting posture on the bicycle. Includes weight data and the spacing between the pelvis. This data is immediately passed to the production line, which produces a carbon steel seat for the right driver through the placement process – it takes only one day to deliver the seat.
The second level of self-organizing production is the interconnection of production logistics or process equipment: there is no further central planning and control in the field of large-scale customer customization. Specific machines also do not require fixed configuration specific production steps. Instead, production activities are dynamic and the processes can be changed flexibly and independently. In addition, flexible technologies, automation systems, and processing systems such as robots or laser scanners – all with freely programmable features – need to be considered,†said Dr. Martin Steyer. “The focus of implementing self-organizing production systems is primarily on setting up Time reduction, of course measurement technology and visual inspection system is also very important, no one can predict the way the future products pass the production line, but because Manz fully understands the running path of the product, we can guarantee the quality of the product.
“Manz's newly developed placement process can handle textile fibers, plastic foils, fiber composites such as carbon composites or other flexible materials. Lasers are used to cut flexible webs such as patches into the shape that customers want. Then, According to the principle of additive, these components are combined by laser welding," Dr. Martin Steyer emphasized. In the footwear industry, the patching process has been used for customized large-scale production; at the same time, this method is also used to produce custom-made sports equipment and medical aids. In such applications, customer data entered using the product configurator (such as height, weight, desired color, and special features) is passed to the production line and digitized.
Picture 2: Manz patch process diagram:
In recent years, Manz Technology has actively expanded its cooperation with multi-party companies. In October 2015, Manz signed a cooperation agreement with Adidas Group to assist in the launch of the “SpeedFactory†program. The Adidas was originally designed from prototype, prototype development, trial production to mass production, which took 18 months of production. Shortened to one week, greatly increasing the competitiveness of production. In this project, Manz uses flexible technology and converts custom shoe components, materials and accessory designs into production data for production in a fully automated system. This automated production line can be customized and designed according to the needs of the end consumers, opening up a comprehensive and innovative business model for customers. From the design of the production system to the production of the final product, in addition to achieving local production in the target market, continuous process digitization proves that Manz has successfully applied Industry 4.0 to manufacturing solutions.
With the increasing level of domestic industrial Internet, production in many industries must be closer to customers. For the brand, it is a good opportunity to achieve “local manufacturing†in the “Made in China†product, which is a good opportunity to further promote localization and “Internet + production†development, and create a new production model to help enterprises achieve Personalized customization, to seize the "smart manufacturing" high point.
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